Airbag assembly

ABSTRACT

An airbag assembly (10) includes a reaction device (15), an inflator (20), and an airbag (25). The reaction device (15) includes a first housing member (27) and a second housing member (28). In the completed airbag assembly, the housing members (27) and (28) form a receptacle with a cavity (29) and a deployment opening (30). The housing members (27) and (28) are configured to capture and orient the inflator (20) and/or the airbag (25) in the cavity (29) of the reaction device (15) as the housing members are being coupled together.

RELATED APPLICATIONS

This application is a continuation-in-part application of U.S.application Ser. No. 07/780,260 filed Oct. 21, 1991, and now abandoned,entitled "Air Bag Reaction Can Structure and Method of Assembly." Theentire disclosure of this earlier application is hereby incorporated byreference.

FIELD OF THE INVENTION

The present invention relates to an airbag assembly, in which aninflator and/or an airbag is coupled with a reaction device as thereaction device is being formed.

BACKGROUND AND SUMMARY OF THE INVENTION

An airbag assembly is commonly installed in a vehicle to protect anoccupant in the event of a crash or collision. A typical airbag assemblycomprises a reaction device, an airbag coupled to the reaction device,and an inflator also coupled to the reaction device. The airbag assemblyis generally installed in a vehicle by attaching the reaction device toa structural part of the vehicle.

In the past, various methods have been developed for assembling anairbag assembly. For example, to assemble the airbag assembly shown inU.S. Pat. No. 4,915,410 to Bachelder, an airbag and a cover are securedto a reaction plate. Thereafter, an inflator is attached to the reactionplate to complete the airbag assembly. The attachment of the inflatorparticularly includes placing the inflator in a cradle formed in thereaction plate and securing the inflator in the cradle.

Additionally, to assemble the airbag assembly disclosed in U.S. patentapplication Ser. No. 07/684,664 filed Apr. 12, 1991, for "Air BagInflator and Method of Assembly" (assigned to the assignee of thepresent invention), an airbag is located within, and secured to, areaction can. Thereafter, a portion of an inflator is inserted into aslot in the reaction can and the remaining portion of the inflator issecured to an outside surface of the reaction can.

Further, to assemble the airbag assembly disclosed in U.S. Pat. No.4,153,273 to Risko, an airbag is initially arranged within the cavity ofa reaction can. The inflator is then inserted into the cavity andcoupled to the reaction can. The arrangement of the airbag within theRisko reaction can is such that the inflator traps a portion of theairbag to secure the airbag to the reaction can.

Still further, to assemble the airbag assembly disclosed in U.S. Pat.No. 4,842,300 to Ziomek, et al., an airbag is inserted into a reactioncan and then coupled to the reaction can. The inflator is then insertedthrough a side opening in the reaction can and coupled to the reactioncan.

In the foregoing airbag assemblies, the reaction device (i.e., thereaction plate or the reaction can) is initially formed as a completeunit and the inflator and the airbag are then coupled to the completedreaction device. In contrast, the present invention provides an airbagassembly in which the inflator and/or the airbag is coupled with thereaction device as the reaction device is being formed.

More particularly, the present invention provides an apparatus for usein forming a vehicle airbag assembly which includes an inflator and anairbag. The apparatus comprises a plurality of housing members adaptedto be coupled together to form a reaction device defining an internalcavity. The housing members are configured to capture the inflatorand/or the airbag in the cavity and to retain the inflator and/or theairbag in a predetermined orientation in the cavity as the housingmembers are coupled together.

In certain airbag assemblies according to the present invention, firstand second housing members are configured to capture both a cylindricalinflator and an airbag in the cavity and to retain both the airbag andthe inflator in respective predetermined orientations in the cavity asthe housing members are coupled together. The inflator includes aplurality of nozzles arranged to ensure that inflation fluid isuniformly directed into the airbag. The airbag includes a foldedinflatable bag and a retainer attached to a portion of the bag. Thefirst and second housing members are essentially identical and eachdefines a cradle for receiving a portion of the inflator and a channelfor receiving a selected part of the airbag retainer.

In one of these airbag assemblies, the inflator-receiving cradlesinclude springs formed in one piece with the housing members. Thesesprings are located so as to engage the exterior of the inflator and topress the inflator resiliently against the other housing members as thehousing members are coupled together. This feature enables inflators ofdifferent dimensions to be supported by a single set of housing membersdesigned to form a single size reaction device.

In another of these airbag assemblies, the housing members areconfigured to form a venturi channel extending between the inflator andthe airbag when the housing members are coupled together. The housingmembers are also shaped so that the reaction device defines anelliptical deployment opening. This airbag assembly further includes acover and a band, and the housing members are configured so that theband may be tensioned around the cover to couple the cover to thereaction device.

In another airbag assembly according to the present invention, the firstand second housing members are configured to capture both a cylindricalinflator and an airbag in the cavity and to retain both the airbag andthe inflator in respective predetermined orientations in the cavity asthe housing members are coupled together. The inflator includes aplurality of nozzles arranged in a 360° pattern. A diffuser is providedto direct the inflation fluid uniformly towards the airbag. The diffuseris incorporated into the airbag by having the housing members configuredto capture the diffuser and to retain the diffuser in a predeterminedorientation in the cavity as the housing members are coupled together.The airbag additionally includes a folded inflatable bag and a retainerattached to a portion of the bag. The first and second housing membersare essentially identical and each defines a cradle for receiving aportion of the inflator and a channel for receiving a selected part ofthe airbag retainer.

In another airbag assembly according to the present invention, first andsecond housing members are configured to capture both a toroidalinflator and an airbag in the cavity and to retain both the airbag andthe inflator in respective predetermined orientations in the cavity asthe housing members are coupled together. The airbag includes a foldedinflatable bag and a retainer attached to a portion of the bag. Thefirst and second housing members are essentially identical and eachdefines a cradle for receiving a portion of the inflator and a channelfor receiving a selected part of the airbag retainer. In modifiedversions of this assembly, the first and second housing members areconfigured to capture one or more toroidal inflators and an airbag inthe cavity and to retain both the airbag and the inflators in respectivepredetermined orientations in the cavity as the housing members arecoupled together.

In another airbag assembly according to the present invention, first andsecond housing members are configured to capture an airbag in the cavityand to retain the airbag in a predetermined orientation in the cavity asthe housing members are coupled together. The airbag includes a foldedinflatable bag and a retainer attached to a portion of the bag. Thefirst and second housing members are essentially identical and eachdefines a channel for receiving a selected part of the airbag retainer.At least one of the housing members is configured to accommodate theexternal mounting of a toroidal inflator.

In yet another airbag assembly according to the present invention, firstand second housing members are configured to capture a cylindricalinflator in the cavity and to retain the inflator in a predeterminedorientation in the cavity as the housing members are coupled together.The inflator includes a plurality of nozzles arranged in a 360° pattern.A diffuser is provided to direct the inflation fluid uniformly towardsthe airbag. Specifically, the diffuser is incorporated into one of thehousing members. An airbag and a cover can be subsequently coupled tothe reaction device to complete the airbag assembly.

Further features of the present invention will become apparent from thefollowing detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an airbag assembly 10 according to thepresent invention;

FIG. 2 is an exploded pre-assembly perspective view of the airbagassembly 10;

FIG. 3 is a perspective partially assembled view of the airbag assembly10;

FIG. 4 is a sectional view of the airbag assembly 10, takensubstantially along the plane described by the line 4--4 of FIG. 1;

FIG. 5 is an exploded perspective view of an airbag assembly 110according to the present invention;

FIG. 5A is an exploded pre-assembly perspective view of a modifiedversion of the airbag assembly 110, namely an airbag assembly 110';

FIG. 6 is a side view of an airbag assembly 210 according to the presentinvention;

FIG. 7 is an exploded pre-assembly perspective view of the airbagassembly 210;

FIG. 8 is a side view, partially in section, of an airbag assembly 310according to the present invention;

FIG. 9 is a front perspective view of the airbag assembly 310;

FIG. 10 is a side view, partially in section, of a modified version ofthe airbag assembly 310, namely an airbag assembly 310';

FIG. 11 is an exploded pre-assembly perspective view of an airbagassembly 410 according to the present invention;

FIG. 12 is a perspective partially assembled view of the airbag assembly410;

FIG. 13 is a side view, partially in section, of the airbag assembly410;

FIG. 14 is a perspective view of an airbag assembly 510 according to thepresent invention;

FIG. 15 is an exploded pre-assembly perspective view of the airbagassembly 510;

FIG. 16 is a top plan view of a modified version of the airbag assembly510, namely an airbag assembly 510';

FIG. 17 is a top plan view of another modified version of the airbagassembly 510, namely an airbag assembly 510";

FIG. 18 is a top plan view of yet another modified version of the airbagassembly 510, namely an airbag assembly 510"';

FIG. 19 is a perspective view of an airbag assembly 610 according to thepresent invention;

FIG. 20 is a sectional view of the airbag assembly 610, takensubstantially along the plane described by the line 20--20 of FIG. 19;

FIG. 21 is a sectional view of a modified version of the airbag assembly610, namely an airbag assembly 610';

FIG. 22 is a sectional view of another modified version of the airbagassembly 610, namely an airbag assembly 610"; and

FIG. 23 is an exploded pre-assembly perspective view of an airbagassembly 710 according to the present invention.

DETAILED DESCRIPTION

Referring now the drawings, various airbag assemblies according to thepresent invention are shown. Specifically, an airbag assembly 10 isshown in FIGS. 1-4, an airbag assembly 110 is shown in FIGS. 5-5A, anairbag assembly 210 is shown in FIGS. 6-7, an airbag assembly 310 isshown in FIGS. 8-10, an airbag assembly 410 is shown in FIGS. 11-13, anairbag assembly 510 is shown on FIGS. 14-18, an airbag assembly 610 isshown in FIGS. 19-22, and an airbag assembly 710 is shown in FIG. 23. Asis explained in more detail below, each of the airbag assembliesaccording to the present invention includes a reaction device formed bya plurality of housing members adapted to be coupled together. In eachassembly, the housing members are configured to capture and orient aninflator and/or an airbag in the cavity of the reaction device as thehousing members are being coupled together. In this manner, the inflatorand/or the airbag is coupled with the reaction device as the reactiondevice is being formed.

Airbag Assembly 10

The airbag assembly 10 (FIGS. 1-4) includes a reaction device 15, acylindrical inflator 20 and an airbag 25. ("Cylindrical" in the contextof the present application means a structure having an axial dimensionsubstantially greater than its radial dimension.) The reaction device 15includes a first housing member 27 and a second housing member 28. Inthe completed airbag assembly 10, the housing members 27 and 28 form areceptacle with a cavity 29 and a deployment opening 30. As is explainedin more detail below, the housing members 27 and 28 are configured tocapture and orient the cylindrical inflator 20 and the airbag 25 in thecavity 29 as the housing members are being coupled together. Althoughnot specifically shown in the drawings, the airbag assembly 10 may alsoinclude a cover for the deployment opening 30. Such a cover would bedesigned to separate into segments during deployment of the airbagassembly 10.

The first and second housing members 27 and 28 are preferably formed bydrawing or stamping aluminum, steel or other appropriate material intothe desired shape. The first housing member 27 includes a base plate 32,generally parallel side walls 33 and 34, and a front wall 35. (See FIG.2.) The side walls 33 and 34, and the front wall 35, are preferablyformed in one piece with the base plate 32. The side walls 33 and 34extend upwardly from opposite side ends of the base plate 32. The frontwall 35 extends upwardly from the front end (i.e., the end closest tothe inflator 20 in the completed airbag assembly 10) of the base plate32 and interconnects the front ends of the side walls 33 and 34. Therear end (i.e., the end closest to the airbag 25 in the completed airbagassembly 10) of the base plate 32 and the rear ends of the side walls 33and 34 together form a rear edge 36 which partially defines thedeployment opening 30 in the completed reaction device 15.

The first housing member 27 further includes a flange 37 which extendsat least partially around its periphery. More particularly, the flange37 projects perpendicularly outward from the upper edges of the side andend walls 33, 34, and 35. (See FIG. 2.) Apertures 38 may be provided inthe flange 37 for coupling the housing members 27 and 28 together and/orfor coupling the reaction device 15 to a structural part of the vehicle.

The first housing member 27 further includes an inflator supportstructure 40 and an airbag support structure 45. The inflator supportstructure 40 comprises a generally U-shaped cradle 51 which is shapedand sized to surround the inflator 20 closely in the completed airbagassembly 10. The cradle 51 is formed by the front wall 35 and a ridge 52which projects upwardly from the base plate 32. The ridge 52 preferablyextends substantially parallel to the rear edge 36 and the front wall35.

The inflator support structure 40 additionally includes a pair ofsemi-circular notches 53, one formed in each of the side walls 33 and34, to accommodate certain components of the inflator 20. (The notches53 cause a slight interruption in the flange 37.) The inflator supportstructure 40 also includes a pair of apertures 54 formed in the frontwall 35. As is explained in more detail below, the apertures 54cooperate with certain locating components of the inflator 20 to ensurethat the inflator is correctly oriented in the completed airbag assembly10.

The airbag support structure 45 includes a channel 55 having a baseportion 56 and side portions 57 and 58. The base portion 56 is formed inthe base plate 32 and the side portions 57 and 58 are formed in the sidewalls 33 and 34. The channel 55 extends substantially parallel to therear edge 36 of the first housing member 27 and is configured to supportthe airbag 25 in a predetermined orientation.

The inflator support structure 40 and the airbag support structure 45are preferably formed in one piece with the first housing member 27. Forexample, the ridge 52 of the inflator support structure 40 can be formedby appropriately drawing or stamping the base plate 32. The airbagsupport structure 45 can be formed by drawing or stamping the channelbase portion 56 into the base plate 32 and by drawing or stamping thechannel side portions 57 and 58 into the side walls 33 and 34.

The second housing member 28 is essentially identical to the firsthousing member 27. Accordingly, the second housing member 28 includes aninflator support structure 65, an airbag support structure 67, a rearedge 68, and a flange 69 with apertures 70. These components aresubstantially the same as analogous components in the first housingmember 27, thus, only certain items are specifically numbered in thedrawings. It may be noted however, that the second housing member 28does not include a pair of apertures in its front wall analogous to theapertures 54 of the first housing member 27.

The inflator 20 comprises a cylindrical housing 76 which encloses asource of inflation fluid (not shown) such as a combustible chemicalmixture and/or a quantity of gas. Squib wires 77 project outwardly fromone end of the cylindrical housing 76 and are electrically connected toa collision sensor (not shown). A plurality of dispensing nozzles 78 arelocated on a rear portion of the cylindrical housing 76. At the onset ofa collision, an ignition device (which includes the squib wires 77)ignites the chemical mixture and/or opens the container of gas. A largequantity of an inert, non-toxic gaseous inflation fluid, such asnitrogen, is thereby released and directed out of the inflator housing76 through the nozzles 78. The arrangement of the nozzles 78 on the rearportion of the inflator housing 76 ensures that the inflation fluid isuniformly directed into the airbag 25.

To ensure that the inflator 20 is correctly oriented in the completedairbag assembly 10, locator members 79 are provided. The locator members79 extend radially outward from a front portion of the housing 76. (SeeFIG. 4.) As is explained in more detail below, the locator members 79cooperate with the apertures 54 in the front wall 35 of the firsthousing member 27 during assembly of the airbag assembly 10.

The inflator housing 76 may also be constructed in the manner set forthin U.S. Pat. No. 4,938,501, which is assigned to the assignee of thepresent invention.

The airbag 25 includes a folded inflatable bag 80 which is formed from afabric such as nylon and which includes a mouth 81 defining an inflationfluid inlet. The airbag 25 also includes a retainer in the form of acontinuous frame 82. The continuous frame 82 is generally rectangular inshape and includes parallel side members 83 and 84 and parallel top andbottom members 85 and 86. The frame 82 is preferably formed in one piecefrom a relatively rigid material, such as aluminum, steel or a polymericmaterial. The continuous frame 82 is attached to the mouth 81 of the bag80 by a suitable attachment technique, for example, stitching oradhesives. Preferred attachment techniques are set forth in U.S. patentapplication Ser. No. 07/629,427 which is entitled "Vehicle Air BagModule and Method of Assembly" and which is assigned to the assignee ofthe present invention.

In the assembly of the airbag assembly 10, the inflator 20 and theairbag 25 are initially placed in predetermined orientations in thefirst housing member 27. More particularly, the continuous frame 82 ofthe airbag 25 is appropriately positioned within the channel 55 of theairbag support structure 45. (See FIG. 3.) When appropriatelypositioned, the frame bottom member 86 is located within the baseportion 56 of the channel 55. (See FIG. 4.) Additionally, the frame sidemembers 83 and 84 are partially located within, and project upwardlyfrom, the side portions 57 and 58 of the channel 55.

When the inflator 20 is placed in its predetermined orientation in thefirst housing member 27, it is properly positioned within the cradle 51of the inflator support structure 40. (See FIG. 2.) In this position,the squib wires 77 of the inflator 20 extend outwardly through eitherthe notch 53 in the side wall 33 or the notch 53 in the side wall 34.Additionally, the locator members 79, which extend radially outward fromthe inflator housing 76, are received by the apertures 54, which arelocated in the front wall 35 of the first housing member 27. Thepositioning of the locator members 79 and the apertures 54 allows onlyone orientation of the inflator 20. In this orientation, the squib wires77 extend through the notch 53 in the side wall 33. Further, in thisorientation, the dispensing nozzles 78 are properly positioned relativeto the deployment opening 30. If necessary or desirable, nuts 95 (oranother suitable fastener) can be drawn down on the locator members 79.

Once the inflator 20 and the airbag 25 have been properly positionedwithin the first housing member 27, the second housing member 28 isplaced adjacent to (or, in the illustrated orientation, placed over) thefirst housing member 27. More particularly, the second housing member 28is aligned with the first housing member 27 in such a manner that theinflator 20 and the airbag 25 are supported in predeterminedorientations within the cavity 29. In these predetermined orientations,the inflator 20 is supported between the cradles of the first and secondinflator support structures 40 and 65, while the airbag 25 is supportedbetween the channels of the first and second airbag support structures45 and 67. When the first and second housing members 27 and 28 arealigned in this manner, the peripheral flanges 37 and 69 are located inadjacent, side-by-side relation, and the apertures 38 and 70 are alignedwith each other.

The first and second housing members 27 and 28 are then coupled togetherusing any suitable method. For example, conventional fasteners, such asrivets 96, may be inserted through the apertures 38 and 70. Additionallyor alternatively, the edges of the flanges 37 and 69 may be crimpedtogether. In any event, the outward perpendicular projection of theflanges 37 and 69 will facilitate the coupling together of the housingmembers 27 and 28 by automated mass production assembly techniques.

Airbag Assembly 110

The airbag assembly 110 (FIG. 5) includes a reaction device, acylindrical inflator 120 and an airbag 125. (Again, "cylindrical" in thecontext of the present application means a structure having an axialdimension substantially greater than its radial dimension.) The reactiondevice includes a first housing member 127 and a second housing member128. These housing members are configured to capture and orient thecylindrical inflator 120 and the airbag 125 in the cavity of thereaction device as the housing members are being coupled together.

The housing members 127 and 128, and thus the reaction device of theairbag assembly 110, are in many ways similar to the analogouscomponents of the airbag assembly 10. For example, the first housingmember 127 includes an inflator support structure 140 and an airbagsupport structure 145. The second housing member 128 includes aninflator support structure 165 and an airbag support structure 167.

The airbag support structures 145 and 167 are essentially identical tothe airbag support structures 45 and 67 of the airbag assembly 10.However, the inflator support structures 140 and 165 differ slightlyfrom the inflator support structures 40 and 65 of the airbag assembly10. Specifically, the semi-circular notch 153 on the side wall 133 ofthe first housing member 127, and the semi-circular notch on thecorresponding side wall of the second housing member 128, are sized toaccommodate a portion of the inflator housing, rather than to functionsimply as an outlet port for the squib wires. Additionally, the cradleof the inflator support structure 140 includes a semi-circular trough toaccommodate certain orientation components of the airbag assembly 110.(The trough of the first housing member 127 is not visible in theillustrated view, but the trough 168 of the second housing member 128 isshown.) A semi-circular notch is not provided on the side wall 134 ofthe first housing member 127 and a semi-circular notch is likewise notprovided on the corresponding side wall of the second housing member128. Additionally, the front wall 135 of the first housing member 127does not include apertures analogous to the inflator-alignment apertures54 in the front wall 35 of the airbag assembly 10.

The inflator 120 comprises a cylindrical housing 176 which contains asource of inflation fluid (not shown). In the illustrated inflator 120,the cylindrical housing 176 is bottle-shaped and includes a neck 176a.The source of inflation fluid preferably comprises an inert, non-toxicpressurized gas, such as argon, nitrogen or air, which may be heatedand/or supplemented by a mixture of combustible materials.

Squib wires 177 project outwardly from the distal end of the neck 176aand are electrically connected to a collision sensor (not shown). Aplurality of dispensing nozzles 178 are located around the entireperiphery of the neck 176a of the bottle-shaped housing 176. At theonset of a collision, an activation assembly (which includes the squibwires 177) releases the pressurized inflation fluid so that it flowsthrough the nozzles 178 in a 360° pattern. This pattern of fluid flowresults in the inflator 120 being a "neutral-thrust" inflator.

Because the dispensing nozzles 178 are arranged in a 360° pattern aroundthe inflator housing 176 (as opposed to being located only on a rearportion of the housing as in the inflator 20), the inflation fluid isnot all directed towards the airbag 125. As such, inflators such as theinflator 120 are often used in conjunction with a diffuser which isdesigned to direct the inflation fluid uniformly into the airbag 125. Inthe illustrated airbag assembly 110, a diffuser is incorporated into theairbag 125, as is explained in more detail below. However,alternatively, a diffuser could be incorporated into the inflatorhousing. A further alternative is to provide a separate cylindricaldiffuser, which is dimensioned to surround the inflator housing. (Seee.g., U.S. Pat. No. 5,131,680 which is assigned to the assignee of thepresent invention.) It should be noted that with some inflators, adiffuser may not be necessary.

The airbag 125 includes a folded inflatable bag 180, a retainer in theform of a rectangular continuous frame 182, and a diffuser plate 188.The bag 180 and the continuous frame 182 are of the same general shapeand construction as the bag 80 and the frame 82 of the airbag assembly10. The diffuser plate 188 may be made of the same material as the frame182 (i.e., aluminum, steel or a polymeric material). In the illustratedairbag assembly 125, the plate 188 is attached to, or formed in onepiece with, the continuous frame 182 in such a manner that itinterconnects the top, bottom and side members of the frame. (The plate188 could constitute only a partial cover if necessary or desired.) Theplate 188 includes a plurality of openings or slots 189. In thecompleted airbag assembly 110, the plate 188 and the inflator supportstructures 140 and 167 together form a mixing chamber around theinflator 120. In this manner, inflation fluid flows through the nozzles178 in a 360° pattern, into the mixing chamber, through the openings 189in the diffuser plate 188, and into the bag 180.

The continuous frame 182, with the diffuser plate 188 secured to theframe, may be attached to the bag 180 in the same manner as the frame 82is attached to the bag 80. Alternatively, and as illustrated, apertures190 may be provided in the continuous frame 182 so that the mouth of thebag 180 may be attached to the frame 82 by suitable fasteners, such asrivets (not shown). If the latter method of attachment is used, the bag180 is preferably provided with welting around its mouth.

Instead of the diffuser being attached to the frame 182, a separatediffuser plate could be formed with frontwardly extending peripheralflanges. In the completed airbag assembly 110, the flanges would becaptured between the frame 182 and the rectangular channel formed by theairbag support structures 145 and 167. In this modified version of theairbag 125, the diffuser plate would also be captured and oriented bythe housing members 127 and 128 as they are being coupled together.

The airbag assembly 110 further includes a mounting cushion 192 and agas seal/mounting cushion 193. The mounting cushion 192 is a ring-likestructure made of a resilient material. In the completed airbag assembly110, the mounting cushion 192 is positioned around the wider (i.e.non-necked) portion of the inflator housing 176 and positioned withinthe semi-circular trough of the inflator support structures 140 and 165.The gas seal/mounting cushion 193 is a cylindrical structure made of amaterial which is resilient and which is also substantially imperviousto the inflation fluid. In the completed airbag assembly 110, the gasseal/mounting cushion 193 is positioned around the distal end of theinflator neck 176a (beyond the nozzles 178) and is positioned betweenthe notch 153 in the side wall 133 of the first housing member 127 andthe analogous notch in the side wall of the second housing member 128.

In the assembly of the airbag assembly 110, the mounting cushions 192and 193 are initially positioned around the inflator 120. Thereafter,the assembly of the airbag assembly 110 is essentially the same as theassembly of the airbag assembly 10. Specifically, the airbag 125 and theinflator 120 are initially placed in predetermined orientations in thefirst housing member 127. The placement of the inflator 120 particularlyincludes locating the bottle-shaped inflator housing 176 within thecradle of the inflator support structure 140 in such a manner that themounting cushion 192 rests within the semi-circular trough and themounting cushion 193 rests in the semi-circular notch 153. One advantageof the inflator 120 is that it does not have to be radially alignedwithin the reaction device. In other words, because the nozzles 178 arearranged in a 360° pattern, the inflator 120 may be located in anyrotational orientation within the inflator support structure 140.Accordingly, inflator orientation components (such as the apertures 54and the locator members 79 of the airbag assembly 10) are not necessary.

The second housing member 128 is then placed over, and aligned with, thefirst housing member 127. When properly aligned, the mounting cushion192 is positioned between the troughs of the first and second inflatorsupport structures. Additionally, the distal end of the inflator neck176a will project through the opening formed by the semi-circularnotches of the housing members 127 and 128. In this manner, the squibwires 177 may extend outwardly from the reaction device in the completedairbag assembly 110. The mounting cushion 193 forms a gas seal tominimize the escape of inflation fluid during deployment of the airbagassembly 110. Additionally, because of the resilient nature of themounting cushions 192 and 193, they are able to accommodate slight sizevariations in the inflator housing 176 caused by temperature changes.

Thereafter, the housing members 127 and 128 are coupled together usingany suitable method, such as the methods discussed above in conjunctionwith the assembly of the airbag assembly 10. It is important, however,that the flanges of the housing members 127 and 128 be tightly sealed toprevent the escape of inflation fluid. Otherwise, there will beincreased likelihood of the loss of fluid due to the 360° pattern of thedispensing nozzles 178.

A modified version of the airbag assembly 110, namely an airbag assembly110', is shown in FIG. 5A. (Analogous parts are designated by likereference numerals, with the parts of the airbag assembly 110' beingfollowed by a single prime (').) The cradle of the inflator supportstructure 140' includes a pair of semi-circular troughs to accommodatecertain orientation components of the airbag assembly 110'. (The troughsof the first housing member 127' are not visible in the illustratedview, but the troughs 168' of the second housing member 128' are shown.)

Instead of a ring-like mounting cushion 192, the airbag assembly 110'includes two pairs of arc-shaped mounting cushions 192'. (The bottompair of cushions 192 are shown, but the top pair of cushions are notvisible in the illustrated view.) In the completed airbag assembly 110',the mounting cushions 192' are positioned around the wider (i.e.non-necked) portion of the inflator housing 176' and positioned withinthe semi-circular troughs of the inflator support structures 140' and165'.

The airbag assembly 110' additionally includes a cylindrical gasseal/mounting cushion 193'. In the illustrated airbag assembly 110', thegas seal/mounting cushion 193' is positioned around the squib wires 177'and will be positioned between the notch 153' in the side wall 133' ofthe first housing member 127' and the analogous notch in the side wallof the second housing member 128' in the completed airbag assembly.However, it is possible to locate the squib wires 177' in differentplaces within the reaction device.

In the assembly of the airbag assembly 110', the mounting cushions 192'are initially placed in the semi-circular troughs of the inflatorsupport structures 140' and 165'. Additionally, the mounting cushion193' is placed around the squib wires 177' of the inflator 120'.Thereafter, the assembly of the airbag assembly 110' is essentially thesame as the assembly of the airbag assembly 110.

Airbag Assembly 210

The airbag assembly 210 (FIGS. 6-7) includes a reaction device 215, acylindrical inflator 220 and an airbag 225. The reaction device 215includes a first housing member 227 and a second housing member 228.These housing members are configured to capture and orient the inflator220 and the airbag 225 in the cavity of the reaction device 215 as thehousing members are being coupled together.

The housing members 227 and 228, and thus the reaction device 215, arein many ways similar to the analogous components of the airbag assembly10. However, in the airbag assembly 210, the side walls 233 and 234 ofthe first housing member 227 are tapered in height from the rear to thefront. The side walls of the second housing member 228 are similarlytapered. Thus, when the first and second housing members 227 and 228 arecoupled together, the height of the reaction device 215 increases towardthe deployment opening 230. (See FIG. 6.) This tapered shape is believedto aid in the aspiration of air into the reaction device 215 during theinflation process.

The first housing member 227 includes an inflator support structure 240and an airbag support structure 245. These structures are similar to,but not the same as, the analogous structures of the airbag assembly 10.More particularly, the inflator support structure 240 includes a seriesof spring-like sections or fingers 246 designed to flexibly engage theinflator 220. The fingers 246 are preferably formed in one piece withthe first housing member 227, and more preferably are formed bydie-cutting its base plate 232. In the illustrated airbag assembly 210,the fingers 246 are arranged in two rows to form a cradle 251 forreceiving the inflator 220.

The fingers 246 are designed to bend slightly to conform to the outerdimensions of the inflator 220. As is explained in more detail below,this feature of the inflator support structure 240 is believed to makethe reaction device 215 compatible with a range of inflators.Additionally, the fingers 246 are also believed indirectly to facilitateinflation of the airbag 225. Particularly, the openings formed by thedie-cutting of the fingers 246 in the housing member 227 allow air to bedrawn into the reaction device 215 during the inflation process.

Another difference between the inflator support structure 240 of theairbag assembly 210 and the inflator support structure 40 of the airbagassembly 10 is the design of the inflator orienting components.Particularly, the notch 253 in the side wall 233 of the first housingmember 227 differs from the semi-circular notch 53. (The notch 253 inthe side wall 234 is essentially the same as the notch 53 in the sidewall 34 of the airbag assembly 10.) More particularly, the upper portionof the notch 253 is shaped to accommodate the bottom half of a D-shapedstud and the lower portion of the notch constitutes an elliptical slot.Thus, the notch 253 has a non-symmetrical shape. Additionally, the frontwall 235 of the first housing member 227 does not include aperturesanalogous to the inflator-alignment apertures 54 in the front wall 35 ofthe airbag assembly 10.

The airbag support structure 245 of the first housing member 227 isalmost identical to the airbag support structure of the airbag assembly10 except that it includes rectangular notches 256 formed in the upperends of the channel 255. (The notches 256 cause interruptions in theflange 237.) As is explained in more detail below, the notches 256accommodate certain components of the airbag 225. Additionally, incontrast to the airbag support structure 45 of the airbag assembly 10,apertures 257 are formed in the base portion of the channel 255. It maybe noted for future reference that the apertures 257 are spacedrelatively close to each other.

The second housing member 228 includes an inflator support structure 265(which includes fingers 266) and an airbag support structure 267. Theinflator support structure 265 of the second housing member 228 isessentially identical to the inflator support structure 240 of the firsthousing member 227. The airbag support structure 267 of the secondhousing member 228 is essentially the same as the airbag supportstructure 245 of the first housing member 227 except for the spacing ofthe apertures in the channel. Specifically, the apertures 275 formed inthe channel of the airbag support structure 267 are spaced farther apartthan the apertures 257. As is explained in more detail below, thisspacing insures the correct orientation of the airbag 225 relative tothe reaction device 215.

The inflator 220 comprises a cylindrical housing 276 which encloses asource of inflation fluid (not shown) such as a combustible chemicalmixture and/or a quantity of gas. Squib wires 277 project outwardly fromone end of the cylindrical housing 276 and are electrically connected toa collision sensor (not shown). A plurality of dispensing nozzles 278are located on a rear portion of the cylindrical housing 276. Theinflator 220 additionally includes orientation components, particularlya threaded D-shaped stud 279a and a pair of locator pins 279b. Theseorientation components extend outwardly from one end of the housing 276,specifically the end opposite the squib wires 277.

A cylindrical inflator which may be used in the airbag assembly 210 isdisclosed in U.S. Pat. No. 4,938,501 to Wipasuramonton which is assignedto the assignee of the present invention.

The airbag 225 includes a folded inflatable bag 280 and a retainer inthe form of a continuous frame 282. The bag 280 and the frame 282 aregenerally of the same construction as the analogous components 80 and 82of the airbag assembly 10. However, in the frame 282, locator studs 287project upwardly from the top member 285 and locator studs 288 projectdownwardly from the bottom member 286. The locator studs 287 and 288 arepreferably integrally formed with the upper and lower members of thecontinuous frame 282. Additionally, in contrast to the bag 80 of theairbag assembly 10, the mouth of the bag 280 includes holes (notspecifically shown) arranged to receive the locator studs 287 and 288.In the assembly process, the locator studs 287 and 288 coordinate withthe apertures 257 and 275 in the airbag support structures.Consequently, the locator studs 287 are spaced differently (i.e. fartherapart) than the locator studs 288.

The continuous frame 282 additionally includes (in contrast to the frame82 of the airbag assembly 10) a pair of tabs 289. The tabs 289 arepreferably formed in one piece with, and project outwardly from, theside members 283 and 284 of the continuous frame 282. The tabs 289provide additional support for the continuous frame 282 and discouragedislodgement of the frame 282 from the reaction device 215 duringdeployment of the airbag assembly 210. However, the use of a "tab-less"frame 282 in the airbag assembly 210 is possible with, and contemplatedby, the present invention.

The assembly of the airbag assembly 210 is essentially the same as theassembly of the airbag assembly 10. Specifically, the airbag 225 and theinflator 220 are initially placed in predetermined orientations in thefirst housing member 227. The placement of the airbag 225 includesinserting the locator studs 288 through the apertures 257 of the firstairbag support structure 245. The different spacing arrangement of theapertures 257 and 275, and the different spacing arrangement of thelocator studs 287 and 288, ensures that the airbag 225 is correctlyoriented relative to the reaction device 215. The placement of theairbag 225 also includes positioning the tabs 289 of the continuousframe 282 in the notches 256 formed on the upper ends of theairbag-supporting channel 255.

The placement of the inflator 220 particularly includes positioning theinflator 220 within the cradle 251 formed by the fingers 246. Whencorrectly positioned, the D-shaped stud 279a and the lower locator pin279b are received within the slot 253 in the side wall 233. Thenon-symmetrical shape of the D-shaped stud 279a, and the correspondingnon-symmetrical shape of the slot 253, ensures that the inflator nozzles278 are correctly oriented relative to the deployment opening 230. Inthis position, the squib wires 277 of the inflator 220 extend outwardlythrough the notch 253 in the side wall 234.

The second housing member 228 is then placed over, and aligned with, thefirst housing member 227. When this step is properly completed, thelocator studs 287 on the continuous frame 282 project through theapertures 275 in the channel of the second airbag support structure 267.Additionally, the tabs 89 of the continuous frame 282 are captured inthe openings formed by the slots 256 of the airbag support structure 245and the corresponding slots of the airbag support structure 267.

When the inflator 220 is positioned between the housing members 227 and228, the inflator-supporting fingers 246 and 266 bend to conform to theouter dimensions of the inflator housing 276. (See FIG. 6.) As such, anexact fit is not necessary between the inflator 220 and the inflatorsupport structures 240 and 265. Consequently, inflators of differentdiameters may be used without structural modification of the housingmembers 227 and 228. The reaction device 215 is therefore compatiblewith a variety of commercially-available inflators.

The housing members 227 and 228 are coupled together using any suitablemethod, such as the methods discussed above in conjunction with theassembly of the airbag assembly 10. For example, conventional fasteners,such as rivets 296, may be inserted through the apertures in the flanges237 and 269. Suitable fasteners (not shown) may also be drawn down onthe locator studs 287 and 288. Additionally or alternatively, a washer297 and a nut 298 may be drawn down on the threaded stud 279a.

Airbag Assembly 310

The airbag assembly 310 (FIGS. 8-9) includes a reaction device 315, acylindrical inflator (not visible in the illustrated views) and anairbag (also not visible in the illustrated views). The reaction device315 includes a first housing member 327 and a second housing member 328.These housing members are configured to capture and orient thecylindrical inflator and the airbag in the cavity 329 of the reactiondevice 315 as the housing members are being coupled together.

The airbag assembly 310 also includes a cover 331 for the deploymentopening 330. The cover 331 includes an elliptical door 331a, a couplingflange 331b, and coupling projections 331c. The door 331a is adapted toseparate into segments during deployment of the airbag assembly 310. Thecoupling flange 331b extends generally perpendicularly from thecircumferential edge of the door 331a. The projections 331c are arrangedin spaced relation around the inner surface of the coupling flange 331band project inwardly from this surface. As is explained in more detailbelow, the coupling flange 331b and the projections 331c are used toattach the cover 331 to the reaction device 315.

The housing members 327 and 328, and thus the reaction device 315, arein many ways similar to the analogous components of the above-describedairbag assemblies. However, the geometry of the housing members 327 and328 differs from those of the airbag assemblies 10, 110 and 210.Particularly, these members are shaped and otherwise designed to createa "venturi" effect within the reaction device 315 during the inflationprocess. The advantages of such a venturi effect in an airbag assemblyare discussed in more detail in U.S. patent application Ser. No.07/618,643, which is entitled "Aspirated Can With Venturi Channel" andwhich is assigned to the assignee of the present application.

More particularly, the front of the first housing member 327 has a shapeincluding an arcuate portion 327a, a narrow neck portion 327b, and asemi-conical portion 327c. In the completed airbag assembly 310, thearcuate portion 327a generously surrounds the cylindrical housing of theinflator. Aspiration openings (not visible for the first housing member327 in the illustrated views) are die-cut or otherwise formed in thearcuate portion 327a. The arcuate portion 327a tapers inwardly towardsthe neck portion 327b and the semi-conical portion 327c slopes outwardlyfrom the neck portion 327b to the airbag support structure 345.

The second housing member 328 includes corresponding portions, namely anarcuate portion 328a, a narrow neck portion 328b, a semi-conical portion328c, and aspiration openings 371.

In the completed reaction device 315, the housing members 327 and 328form a venturi channel within the cavity 329. Specifically, the neckportions 327b and 328b form a throat between the chamber formed by thearcuate portions 327a and 328a and the chamber formed by thesemi-conical portions 327c and 328c. During the inflation process, thisgeometry encourages ambient air to be drawn through the aspirationopenings 371 in the second housing member 328 and the analogous openingsin the first housing member 327. Valve members, such as flexible foilsheets 372, may be provided to prevent the inflation fluid from escapingthrough the aspiration openings during the inflation process.

The first and second housing members 327 and 328 are also designed sothat the deployment opening 330 has an elliptical geometry. (See FIG.9.) To this end, the rear edges 336 and 368 of the housing members 327and 328 are substantially semi-oval in shape. The elliptical shape ofthe deployment opening 330 increases the structural integrity of thereaction device 315 and minimizes fish-mouthing (outward deformation ofthe reaction device) during deployment of the airbag assembly 310.Additionally, the elliptical geometry of the opening 330 is believed tofacilitate the attachment of the cover 331 to the reaction device 315.Still further, the semi-oval (rather than rectilinear) shape of the rearedges 336 and 368 results in the first and second housing members 327and 328 being more compatible with automated production techniques.

The flanges 337 and 369 of the housing members 327 and 328 also differsomewhat from the flanges of the housing members of the airbagassemblies 10, 110 and 210. Specifically, flanges 337 and 369 includesemi-circular indentions 337a and 369a, respectively. In the completedreaction device 315, these indentations provide an ignitor harnessprotector channel for certain components of the inflator, namely itssquib wires 377.

The housing members 327 and 328 also include certain features toaccommodate the cover 331 which are not found in the illustrated airbagassemblies 10, 110 and 210. Specifically, the regions of the housingmembers between their airbag support structures 345 and 365 and theirrear edges 336 and 368 are contoured to accommodate attachment of thecover 331 to the reaction device 315. More specifically, the profile ofthese regions provides an external channel 315a when the housing members327 and 328 are coupled together to form the reaction device 315.Apertures 315b are arranged around the channel 315a in a patterncorresponding to the projections 331c of the cover 331.

In the airbag assembly 310, the airbag support structures 345 and 365are essentially identical to the airbag support structures of the airbagassembly 10 except that the channels are semi-oval, rather thanrectilinear, in shape. However, the inflator support structures of theairbag assembly 310 are of a somewhat different construction than theinflator support structures of the airbag assembly 10. Specifically, theinflator support structures of the airbag assembly 310 includesemi-cylindrical ledges (not visible in the illustrated views) on whichthe ends of the inflator may be supported.

The assembly of the airbag assembly 310 is substantially the same as theassembly of the airbag assembly 10. Specifically, the airbag and theinflator are initially placed in predetermined orientations in the firsthousing member 327. The placement of the inflator includes supportingits ends on the semi-cylindrical ledges of the inflator supportstructure. Additionally, the inflator squib wires 377 are positionedwithin the semi-circular indention 337a of the peripheral flange 337.

The second housing member 328 is then placed over, and aligned with, thefirst housing member 327. Thereafter, the housing members 327 and 328are coupled together using any suitable method, such as the methodsdiscussed above in conjunction with the assembly of the airbag assembly10. For example, conventional fasteners, such as rivets 396, may beinserted through apertures in the flanges 337 and 369. In the completedreaction device 315, the inflator squib wires 377 extend through theignitor harness protector channel formed by the semi-circular indentions337a and 369a of the flanges 337 and 369.

To complete the airbag assembly 310, the cover 331 is coupled to thereaction device 315. Specifically, the coupling flange 331b ispositioned within the external channel 315a of the reaction device 315and projections 331c are inserted into the apertures 315b. A band 397 isthen tensioned around the flange 331b to secure it to the reactiondevice 315 and provide additional integrity for the airbag assembly 310.The band 397 is preferably dimensioned to fit snugly within the channel315b. The elliptical geometry of the opening 330 and/or the channel 315ais believed to allow the band 397 to grasp the cover 331 more uniformly.

A modified version of the airbag assembly 310, namely an airbag assembly310', is shown in FIG. 10. (Analogous parts are designated by likereference numerals, with the parts of the airbag assembly 310' beingfollowed by a single prime (').) In the airbag assembly 310', the airbagis essentially identical to the airbag 225 (rather than the airbag 25)except that the frame 382' is of an elliptical, rather than rectangular,shape. The airbag support structures 345' and 367' are also essentiallyidentical to the airbag support structures 245 and 267 except that therespective channels are of semi-oval, rather than rectilinear, shapes.Consequently, the continuous frame 382' includes locator studs 387' and388' and the channels of the airbag support structures 345' and 367'include corresponding apertures (shown, but not specifically numbered inthe drawing). The cover 331' of the airbag assembly 310' includes anelliptical coupling flange 331b' which is sized to fit within, ratherthan around, the deployment opening 330'. Additionally, instead ofprojections 331c, the coupling flange 331b' is provided with openings331c' arranged to receive the locator studs 387' and 388' of thecontinuous frame 382'.

In the assembly of the airbag assembly 310', the cover 331' isincorporated into the airbag prior to it being positioned within thefirst housing member 327". Specifically, the cover coupling flange 331b'is positioned around the continuous frame 382' and the locator studs387' and 388' are inserted through the openings 331c'. The airbagassembly 310' is then assembled in much the same manner as the airbagassembly 210. In the completed airbag assembly 310', the cover couplingflange 331b' is sandwiched between the continuous frame 382' and thechannels of the first and second airbag support structures 345' and367'.

It may be noted that a cover could be coupled to the airbag assembly 210in a similar manner.

Airbag Assembly 410

The airbag assembly 410 (FIGS. 11-13) includes a reaction device 415, acylindrical inflator 420, and an airbag 425. The reaction device 415includes a first housing member 427 and a second housing member 428.These housing members are configured to capture and orient thecylindrical inflator 420 and the airbag 425 in the cavity of thereaction device 415 as the housing members are being coupled together.

The airbag assembly 410 also includes a cover 431 for the deploymentopening 430. The cover 431 includes a rectangular door 431a, a couplingflange 431b, and coupling apertures 431c. The door 431a is adapted toseparate into segments during deployment of the airbag assembly 410. Thecoupling flange 431b extends generally perpendicularly from theperimetric edge of the door 431a. The apertures 431c are arranged inspaced relation around the top and bottom portions of the flange 431b.As is explained in more detail below, the coupling flange 431b and theapertures 431c are used to attach the cover 431 to the reaction device415.

The housing members 427 and 428 are preferably molded from alight-weight, high-performance thermoplastic material, such as ULTEMfrom GE Plastics of Southfield, Mich. The housing members 427 and 428are in many ways similar to the analogous components of theabove-described airbag assemblies. For example, the first housing member427 includes an inflator support structure 440 and an airbag supportstructure 445. The inflator support structure 440 includes a pair ofgenerally U-shaped cradles 450 and 451 formed in the base plate 432 ofthe first housing member 427. The inner contour of the cradle 450 isgenerally semi-circular except for a flat section 450a which is used fororientation purposes during assembly of the airbag assembly 410. Theinner contour of the cradle 451 is essentially semi-circular, i.e., itdoes not include a flat section. The inflator support structure 440additionally includes a pair of semi-circular notches 453, one formed ineach of the side walls 433 and 434, to accommodate certain components ofthe inflator 420.

The airbag support structure 445 is essentially the same as the airbagsupport structure 45 of the airbag assembly 10 except that a series ofapertures 459 are formed along its channel.

The second housing member 428, which is a substantially identical,mirror-image of the first housing member 427, includes an inflatorsupport structure 465 and an airbag support structure 467. The inflatorsupport structure 465 includes a pair of U-shaped cradles and the airbagsupport structure 467 includes a channel in which apertures 473 areformed.

In contrast to the airbag assemblies 10, 110, 210 and 310, the housingmembers 427 and 428 of the airbag assembly 410 do not include aperipheral flange. Thus, no flanges exist to bolt and/or crimp whencoupling the housing members 427 and 428 together. Instead, the firstand second housing members 427 and 428 include several couplingcomponents which are not included in the earlier discussed airbagassemblies. These components are designed to couple the housing members427 and 428 together in a "fastenerless" fashion.

The coupling components of the housing members 427 and 428 include ahook-and-groove arrangement along the upper/lower edges of the frontwalls of the housing members. Specifically, a first set of hooks 435aand a first set of grooves 435b are located along the upper edge of thefront wall 435 of the first housing member 427. A second set of matinghooks and a second set of mating grooves (not visible in the illustratedviews) are located along the lower edge of the front wall of the secondhousing member 428. To couple the housing members 427 and 428 together,the first set of hooks 435a are engaged and locked with the second setof grooves and, simultaneously, the first set of grooves 435b areengaged and locked with the second set of hooks.

The coupling components of the housing members 427 and 428 also includea stud-bore arrangement along the upper/lower edges of the front wallsof the housing members. Specifically, a locator stud 435c and a locatorbore 435d are situated along the upper edge of the front wall 435 of thefirst housing member 427. A mating locator bore (not visible in thedrawings) and a mating locator stud (also not visible in the drawings)are located along the lower edge of the front wall of the second housingmember 428. These components further facilitate aligning and couplingthe housing members 427 and 428 together during the assembly process andprovide shear load strength for the reaction device 415.

The first and second housing members 427 and 428 also include couplingcomponents for coupling the cover 431 to the reaction device 415. Thesecomponents specifically include hooks 436a located along the rear edge436 of the first housing member 427 and hooks 468a located along therear edge 468 of the second housing member 428.

The inflator 420 comprises a cylindrical housing 476 which encloses asource of inflation fluid (not shown) such as a combustible chemicalmixture and/or a quantity of gas. Squib wires 477 project outwardly fromone end of the cylindrical housing 476 and are electrically connected toa collision sensor (not shown). A plurality of dispensing nozzles 478are located on a rear portion of the cylindrical housing 476. Theinflator 420 additionally includes orientation components, particularlya radial flange 479a and a locator pin 479b. The radial flange 479asurrounds one end of the housing 476 (the same end from which the squibwires 477 extend) and includes a flat section 479c for orientationpurposes. The locator pin 479b extends axially from the other"non-flanged" end of the housing 476.

A cylindrical inflator which may be used in the airbag assembly 410 isdisclosed in U.S. Pat. No. 4,938,501 to Wipasuramonton, which isassigned to the assignee of the present invention.

The airbag 425 includes a folded inflatable bag 480 and a retainer inthe form of a continuous frame 482. The bag 480 and the frame 482 aregenerally of the same construction as the analogous components 80 and 82of the airbag assembly 10. However, in the frame 482, locator studs 487project upwardly from the top member 485 and locator studs 488 projectdownwardly from the bottom member 486. The locator studs 487 and 488 arepreferably integrally formed with the upper and lower members of thecontinuous frame 482. Additionally, in contrast to the bag 80 of theairbag assembly 10, the mouth of the bag 480 includes holes (notspecifically shown) arranged to receive the locator studs 487 and 488.In the assembly process, the locator studs 487 and 488 cooperate withthe apertures 459 and 473 in the airbag support structures 445 and 467.In contrast to the locator studs 287 and 288 discussed above inconnection with the airbag assembly 210, the locator studs 487 and 488are uniformly spaced.

The airbag assembly 410 further includes a pair of resilient siliconinsulators 489 and 490. The insulator 489 includes a pair of molded orextruded sections 489a and 489b, each of which includes an inner grooveand an outer groove. (The grooves are shown but not specificallynumbered in the drawings.) The inner grooves of the insulator sections489a and 489b are sized to receive bottom and top sections of theinflator radial flange 479a. The outer groove of the insulator section489a is sized to receive the supporting edge of the cradle 450 of thefirst inflator support structure 440. The outer groove of the insulatorsection 489b is sized to receive the supporting edge of thecorresponding cradle of the second inflator support structure 465.

The insulator 490 includes a pair of molded or extruded sections 490aand 490b. Each of the insulator sections includes an outer groove sizedto receive the supporting edge of the cradle of the adjacent first orsecond inflator support structure 440 or 465. In contrast to theinsulator sections 489a and 489b, the insulator sections 490a and 490bdo not include inner grooves. Instead, the inner surfaces of theinsulator sections 490a and 490b are relatively smooth for engagementwith the inflator housing 476 adjacent its "non-flanged" end.

In the completed airbag assembly 410, the insulators 489 and 490 areresiliently compressed against the inflator housing 476. Thecompressibility and resilience of the insulators allows for largertolerances between the inflator housing 476 and the reaction device 415.Consequently, the insulators 489 and 490 provide greater flexibility inmanufacturing the inflator 420 for the airbag assembly 410.Additionally, the grooves of the insulator sections 489a and 489b, andtheir engagement with the inflator-supporting cradles and the inflatorflange, tends to restrict both axial and radial movement of the inflator420. Also, the insulators 489 and 490 thermally insulate the housingmembers 427 and 428 from the inflator 420. Thus, the insulators 489 and490 minimize the transmission of vibrations and/or heat between theinflator 420 and the housing members 427 and 428 during the deploymentof the airbag assembly 410.

To assemble the airbag assembly 410, the first housing member 427 isinitially located in a tabletop holding fixture (not shown).Additionally, the sections of the insulators 489 and 490 are initiallypressed onto the respective inflator-supporting cradles of the first andsecond housing members 427 and 428.

The inflator 420 and the airbag 425 are then placed in predeterminedorientations in the first housing member 427. More particularly, thecontinuous frame 482 of the airbag 425 is appropriately positionedwithin the channel 455 of the airbag support structure 445. Thecylindrical inflator 420 is placed in the inflator-supporting cradles450 and 451 and pushed into place to fit snugly within the firstinsulator sections 489a and 490a. When the inflator 420 is properlypositioned, the locator pin 479b projects outwardly through the notch453 in the side wall 433 and the squib wires 477 extend through thenotch 453 in the side wall 434. Additionally, the flat section 479c ofthe inflator flange 479a mates with the flat section 450a of the cradle450, thereby ensuring that the dispensing nozzles 478 are properlypositioned relative to the deployment opening 430 in the completedairbag assembly 410.

Once the inflator 420 and the airbag 425 have been properly positionedwithin the first housing member 427, the second housing member 428 isplaced adjacent to (or, in the illustrated orientation, placed over) thefirst housing member 427. In the illustrated airbag assembly 410, thispositioning includes locking the first set of hooks 435a with the secondset of grooves, locking the first set of grooves 435b with the secondset of hooks, mating the locator stud 435c with the correspondinglocator bore, and mating the locator bore 435d with the correspondinglocator stud. In this manner, the housing members 427 and 428 arecoupled together to form the reaction device 415.

To complete the airbag assembly 410, the cover 431 is coupled to thereaction device 415. Specifically, the coupling flange 431b ispositioned around the deployment opening 430 and the hooks 436a and 468aare inserted through the apertures 431c. A pair of retainer strips 491are provided for insertion into the distal ends of the hooks 436a and468a to lock the cover 431 in place. The retainer strips 491 preferablyalso include apertures to receive the distal ends of the frame locatorstuds 487 and 488. The retainer strips 491 may then be secured to thefirst and second housing members 427 and 428 by conventional fasteningmethods, such as heat staking, sonic welding or attaching pushnuts.

The airbag assembly 410, like all of the airbag assemblies of thepresent invention, is adapted to be coupled to a vehicle. In theillustrated assembly, this adaptation includes bosses 492 formed in thehousing members 427 and 428. Each of the bosses 492 has a bolt hole anda slot. U-clips (not shown) may be pushed onto each boss 492 with oneleg passing through the adjacent slot and the other leg overlying thebolt hole. (The legs of each U-clip have holes which align with the bolthole.) One of these holes is threaded to receive and hold a bolt whichextends through the bolt hole and a hole (not shown) in a structuralpart of the vehicle to mount the assembly on the vehicle.

Additionally or alternatively, an attachment device may be formed oneach side of the reaction device 415 to couple the airbag assembly 410to a structural part of the vehicle. In the illustrated airbag assembly410, each attachment device includes pocket portions 493 which areformed integrally with the housing members 427 and 428. The pocketportions 493 are designed to accommodate a mounting plate 494 from whichthreaded pins 494a project. When the mounting plate 494 is locatedbetween the pocket portions 493 (i.e. when the housing members 427 and428 are coupled together), the pins 494a project outwardly through slotsin each pocket portion. The pins 494a may be coupled with nuts 495 to abracket 496 which is then attached to a structural part of the vehicle.The bracket 496 can be formed in any one of a number of configurationsso as to be compatible with a particular vehicle. Consequently, bymodifying only the bracket 496, the reaction device 415 is compatiblewith a wide range of vehicles.

Airbag Assembly 510

The airbag assembly 510 (FIGS. 14-15) includes a reaction device 515, atoroidal inflator 520, and an airbag 525. ("Toroidal" in the context ofthe present application means a structure having a curved outer surfacewith a radial dimension that is the same or greater than its axialdimension.) The reaction device 515 includes a first housing member 527and a second housing member 528. These housing members are configured tocapture and orient the toroidal inflator 520 and the airbag 525 in thecavity of the reaction device 515 as the housing members are beingcoupled together.

The first and second housing members 527 and 528 are preferably formedby drawing or stamping aluminum, steel or other appropriate materialinto the desired shape. The first housing member 527 includes a baseplate 532, side walls 533 and 534, and a rear wall 535. The side walls533 and 534 are preferably formed in one piece with, and extend awayfrom, opposite ends of the base plate 532. The rear wall 535 alsoextends away from the base plate 532 and interconnects the side walls533 and 534 adjacent their front ends. The rear ends of the base plate532 and the side walls 533 and 534 together define a rear edge 536 whichpartially forms the deployment opening 530 in the completed reactiondevice 515.

The walls of the first housing member 527 are shaped and arranged toaccommodate the toroidal inflator 520. Specifically, the side wall 533includes a rear portion 533a and a front portion 533b. The rear portion533a extends generally perpendicular to the deployment opening 530 andthe front portion 533b tapers generally inwardly towards the rear wall535. Additionally, an indentation 533c is formed in an intermediateregion of the front portion 533b. The side wall 534 includes a similarrear portion 534a, front portion 534b, and indentation 534c. The lengthof the tapered front side wall portions 533b and 534b relative thelength of the rear side wall portions 533a and 534a, and relative to thelength of the rear wall 535, cause the housing member 527 to have aroughly V-shape geometry.

In the illustrated airbag assembly 510, the base plate 532 also includesfeatures to accommodate the toroidal inflator 520. Specifically, asupport pedestal 532a is formed in the bottom surface of the base plate532. Additionally, an aperture 532b is provided in the support pedestal532a. In the completed reaction device 515, the aperture 532b forms asmall passage between the cavity 529 and the exterior of the reactiondevice 515. As is explained in more detail below, the support pedestal532a supports certain components of the inflator 520 in the completedairbag assembly 510.

A flange 537 extends at least partially around the periphery of thefirst housing member 527. More particularly, the flange 537 projectsperpendicularly outwardly from the upper edges of the side walls 533 and534 and the upper edge of the rear wall 535. The outer contour of theflange 537 follows a generally linear profile and is therefore of anincreased thickness adjacent to the indentations 533c and 534c.Apertures 538 may be provided in the flange 537 for coupling the housingmembers 527 and 528 together, for coupling the inflator 520 to thereaction device 515, and/or for coupling the reaction device 515 to astructural part of the vehicle. In the illustrated airbag assembly 510,the apertures 538 are provided adjacent the indentations 533c and 534cand adjacent an intermediate region of the rear wall 535.

The first housing member 527 further includes an inflator supportstructure 540 and an airbag support structure 545. The inflator supportstructure 540 comprises a generally polygonal-shaped cradle 551, inwhich the support pedestal 532a is located. The cradle 551 is formed bythe rear wall 535, the indentations 533c and 534c, and the sections ofthe front portions 533b and 534b of the side walls 533 and 534 extendingbetween the indentations and the rear wall 535. The polygonal-shapedcradle 551 is configured to support the inflator 520 in a predeterminedorientation within the reaction device 515.

The airbag support structure 545 is substantially the same as the airbagsupport structure 45 of the airbag assembly 10. Accordingly, the airbagsupport structure 545 includes a channel 555 which extends Substantiallyparallel to the rear edge 536 of the first housing member 527 and whichis configured to support the airbag 525 in a predetermined orientation.

The second housing member 528 is essentially identical to the firsthousing member 527. The second housing member 528 includes an inflatorsupport structure 565, an airbag support structure 567, a rear edge 568and a flange 569. These components are substantially the same asanalogous components in the first housing member 527 and, thus, onlycertain items are specifically numbered in the drawings. However, thesecond housing member 528 does not include a support pedestal analogousto the support pedestal 532a of the first housing member 527.

The inflator 520 comprises a toroidal housing 576 which encloses asource of inflation fluid (not shown) such as a combustible chemicalmixture. The inflator 520 includes a mounting flange 576a extendingradially from the toroidal housing 576. In the illustrated embodiment,the mounting flange 576a is shaped to form a substantially square borderaround the housing 576. Four apertures 576b are formed on the mountingflange 576a, specifically one in each corner. As is explained in moredetail below, the apertures 576b coordinate with the apertures 538 onthe first housing member 527 and the analogous apertures on the secondhousing member 528 during assembly of the airbag assembly 510. The useof inflators with mounting flanges having other shades (such astriangular) and/or alternate aperture arrangements (such as on only twoof the four corners of a square) are possible with, and contemplated by,the present invention.

The mounting flange 576a may be viewed as separating the housing 576into a dispensing portion 576c and a base portion 576d. In theillustrated embodiment, the dimensions of the dispensing portion 576care greater in the axial direction than the base portion 576d. Squibwires 577 project outwardly from one end of the toroidal housing 576,specifically, the end of the base portion 576d. The squib wires 577 areelectrically connected to a collision sensor (not shown). A plurality ofdispensing nozzles 578 are arranged, in a 360° pattern, around thecurved circumference of the dispensing portion 576c. At the onset of acollision, an ignitor device (including the squib wires 577) ignites thechemical mixture and a large quantity of an inert, non-toxic gaseousinflation fluid, such as nitrogen, is released through the nozzles 578.The inflator 520 may be constructed in the manner described in U.S. Pat.No. 4,902,036.

The airbag 525 is essentially the same as the airbag 25 of the airbagassembly 10. Accordingly, the airbag 525 includes a folded inflatablebag 580 which is formed from fabric such as nylon and which includes amouth 581 defining an inflation fluid inlet. The airbag 525 alsoincludes a retainer in the form of a continuous frame 582. Thecontinuous frame 582 is generally rectangular in shape and is preferablyformed in one piece from a relatively rigid material, such as aluminum,steel or a polymeric material. The continuous frame 582 is attached tothe bag 580 adjacent its mouth 581 by a suitable attachment technique,for example, stitching or adhesives.

In the assembly of the airbag assembly 510, the airbag 525 is initiallyplaced in a predetermined orientation in the first housing member 527.More particularly, the continuous frame 582 is positioned within thechannel 555 of the airbag support structure 545. In the illustratedassembly, the first portion of the frame 582 will be located in thechannel 555 and the second portion of the frame 582 will projectupwardly from the first housing member 527.

The inflator 520 is next placed in a predetermined orientation in thefirst housing member 527. In this predetermined orientation, the baseportion 576d will be positioned within the cradle 551 of the inflatorsupport structure 540. Some alignment of the inflator 520 is necessaryduring this positioning. Specifically, the inflator 520 must be orientedso that the apertures 576b on the mounting flange 576a are aligned withthe apertures 538 on the first housing member 527. In the predeterminedorientation, the square mounting flange 576a will be arranged diagonallyrelative to the deployment opening 530. It may be noted that certainfeatures of the inflator 520 (i.e., the 360° pattern of the dispensingnozzles 578, the square shape of the mounting flange 576a, and the factthat the apertures 576b are provided on all four corners of the mountingflange 576a) allow the inflator to be "correctly" aligned in fourdifferent orientations. During the placement of the inflator 520 in thecradle 551, the base portion 576d is positioned on the support pedestal732a and the squib wires 577 are threaded through the aperture 532b.

Once the inflator 520 and the airbag 525 have been placed in the firsthousing member 527, the second housing member 528 is placed over thefirst housing member. The second housing member 528 is aligned with thefirst housing member 527 in such a manner that the inflator 520 and theairbag 525 are supported in predetermined orientations within the cavity529. In particular, the inflator 520 is supported between the cradles ofthe first and second inflator support structures 540 and 565, while theairbag 525 is supported between the channels of the first and secondairbag support structures 545 and 567. When the first and second housingmembers 527 and 528 are aligned in this manner, the flanges 537 and 569are located in adjacent, side-by-side relation, and their apertures arealigned with each other. Although not specifically shown in thedrawings, appropriate recesses would be provided in the flanges 537 and569 to accommodate the inflator flange 576a.

The first and second housing members 527 and 528 are then coupledtogether. Specifically, three conventional fasteners (not shown) areinserted through the aligned apertures in the second housing flange(apertures not specifically shown or numbered), the first housing flange(apertures 538) and the mounting flange 576a (apertures 576b). Thus, thefasteners, in addition to coupling the housing members together, couplethe inflator 520 to the reaction device 515. For additionalreinforcement, the flanges 537 and 569 may be crimped together.

A modified version of the airbag assembly 510, namely an airbag assembly510', is shown in FIG. 16. (Like parts are designated by like referencenumerals, with the parts of the airbag assembly 510' being followed by asingle prime (').) In the airbag assembly 510', the first and secondhousing members are modified to support two toroidal inflators 520' in apredetermined orientation in the reaction device 515'. Thus, in theairbag assembly 510', the housing members are configured to capture andorient a pair of inflators 520' and the airbag in the cavity of thereaction device 515' as the housing members are being coupled together.

The airbag assembly 510' is essentially identical to the airbag assembly510 except that the housing members are modified to create generallydouble a pair of polygonal cradles for the inflators 520'. Specifically,the first housing member 527' is modified so that the rear side wallportions 533a' and 534a' and the rear wall 535' form a "W" shapeoutline. Additionally, indentations 533c' and 534c' are provided at theouter ends and outer vertexes of the "W" and a pair of indentations535c' are provided at the center vertex of the "W". Apertures 538' arelocated in the flange 537' adjacent each of the indentations. The shapeof the second housing member is modified in a similar manner.

Another modified version of the airbag assembly 510, namely an airbagassembly 510", is shown in FIG. 17. (Like parts are designated by likereference numerals, with the parts of the airbag assembly 510" beingfollowed by a double prime (").) In the airbag assembly 510", the firstand second housing members are designed to support a toroidal inflator520" in a different predetermined orientation in the reaction device515". In this different predetermined orientation, the rear side of thesquare mounting flange 576a" is arranged parallel (as opposed todiagonally) to the deployment opening 530".

The airbag assembly 510" is essentially identical to the airbag assembly510 except that the housing members are modified to create a generallysquare-shaped cradle for the inflator 520". Specifically, the firsthousing member 527" is modified so that the rear side wall portions533a" and 534a" and the rear wall 535" form a "square" outline.Additionally, indentations 533c" and 534c" are provided at the rearcorners of the square, and indentations 535c" are provided at the frontcorners of the square. Apertures 538" are located in the flange 537"adjacent each of the indentations. The shape of the second housingmember is modified in a similar manner. In the completed airbag assembly510", fasteners would be inserted through all four apertures in theinflator mounting flange 576a".

Yet another modified version of the airbag assembly 510, namely anairbag assembly 510"', is shown in FIG. 18. (Like parts are designatedby like reference numerals, with the parts of the airbag assembly 510"'being followed by a triple prime ("').) In the airbag assembly 510"',the first and second housing members are modified to support a pair ofinflators 520"' in a predetermined orientation in the reaction device515"'. In this predetermined orientation, the rear sides of the inflatormounting flanges 576a"' are arranged parallel (as opposed to diagonally)to the deployment opening 530"'. Thus, in the airbag assembly 510"', thehousing members are configured to capture and orient a pair of inflators520"' and the airbag in the cavity of the reaction device 515"' as thehousing members are being coupled together.

The airbag assembly 510"' is essentially identical to the airbagassembly 510 except that the housing members are modified to creategenerally rectangular-shaped cradles for the inflators 520"'.

Specifically, the first housing member 527"' is modified so that therear side wall portions 533a"' and 534a"' and the rear wall 535"' form a"rectangular" outline. In this airbag assembly 510"', the rear side wallportions 533a"' and 534a"' are essentially colinear with the front sidewall portions 533b"' and 534b"'. Additionally, indentations 533c"' and534c"' are provided at the front and rear corners of the rectangle, anda pair of indentations 535c"' are provided at an intermediate portion ofthe rear wall 535"'. Apertures 538"' are located in the flange 537"'adjacent each of the indentations. The shape of the second housingmember is modified in a similar manner. In the completed airbag assembly510"', fasteners would be inserted in three of the four apertures ineach of the inflator mounting flanges 576a"'.

Airbag Assembly 610

The airbag assembly 610 (FIGS. 19-20) includes a reaction device 615, atoroidal inflator 620, and an airbag 625. The reaction device 615includes a first housing member 627 and a second housing member 628.These housing members are configured to capture and orient the airbag625 in the cavity of the reaction device 615 as the housing members arebeing coupled together.

The first and second housing members 627 and 628 are similar in manyways to the first and second housing members 527 and 528 of the airbagassembly 510. For example, the first and second housing members 627 and628 include airbag support structures 645 and 667 which are essentiallyidentical to the airbag support structures of the airbag assembly 510.However, the housing members 627 and 628 do not include inflatorsupporting structures analogous to those of the airbag assembly 510.Instead, one of the housing members (the second housing member 628 inthe illustrated assembly 610) includes an inflator-supporting opening653. Two or more, and preferably four, apertures 654 are arranged in asquare pattern around the inflator-supporting opening 653. As isexplained in more detail below, the inflator-supporting opening 653 andthe apertures 654 are sized and arranged to accommodate an "external"mounting of the inflator 620.

The absence of the inflator supporting structures (or cradles) in thehousing members 627 and 628 results in the front portions of thesemembers having a slightly different profile than the housing members ofthe airbag assembly 510. For example, no indentations (such as theindentations 533c and 534c found in the airbag assembly 510) arenecessary along the side walls of the members. Additionally, the firsthousing member 627 does not include a "squib wire" channel (such as thechannel 532a of the airbag assembly 510).

The inflator 620 is essentially identical to the inflator 520 of theairbag assembly 510. Thus, the inflator 620 comprises a toroidal housing676, a square mounting flange 676a with an aperture 676b on each of itsfour corners, a dispensing portion 676c, and a base portion 676d. Squibwires 677 project outwardly from the base portion 676d and a pluralityof dispensing nozzles 678 are arranged, in a 360° pattern, around theradial side of the dispensing portion 676c. Again, the use of inflatorswith mounting flanges having other shapes (such as triangular) and/oralternate aperture arrangements (such as on only two of the four cornersof a square) are possible with, and contemplated by, the presentinvention.

The airbag 625 is essentially the same as the airbag 25 of the airbagassembly 10. Accordingly, the airbag 625 includes a folded inflatablebag 680 and a retainer in the form of a continuous frame 682.

In the assembly of the airbag assembly 610, the airbag 625 is initiallyplaced in a predetermined orientation in the first housing member 627.More particularly, the continuous frame 682 is positioned within thechannel of the airbag support structure 645. The second housing member628 is then placed over the first housing member 627 and aligned so thatthe airbag 625 is supported in a predetermined orientation within thecavity 629. In particular, the airbag 625 is supported between thechannels of the first and second airbag support structures 645 and 667.When the first and second housing members 627 and 628 are aligned inthis manner, their flanges 637 and 669 are located in adjacent,side-by-side relation.

The first and second housing members 627 and 628 are then be coupledtogether to complete the reaction device 615. In the illustrated airbagassembly 610, this coupling could be accomplished by crimping theflanges 637 and 669 together. Additionally or alternatively, aperturescould be provided in the flanges 637 and 669 for suitable fasteners (notshown).

The inflator 620 is next placed in a predetermined orientation relativeto the reaction device 615. In the predetermined orientation of theillustrated airbag assembly 610, the square mounting flange 676a isarranged diagonally relative to the deployment opening 630. Theplacement of the inflator 620 particularly includes inserting thedispensing portion 676c of the inflator 620 through theinflator-supporting opening 653. As was indicated above, theinflator-supporting opening 653 and the apertures 654 of the secondhousing member 628 are sized and arranged to accommodate an externalmounting of the inflator 620. To this end, the inflator supportingopening 653 is sized so that it is large enough to receive the inflatordispensing portion 676c but small enough to prevent insertion of theinflator mounting flange 676a. Additionally, the apertures 654 arearranged for alignment with the apertures 676b on the inflator mountingflange 676a.

When properly inserted, the mounting flange 676a rests on the outersurface of the second housing member 628 and the base portion 676d willproject upwardly from the flange 676a. Some alignment of the inflator620 is necessary. Specifically, the inflator 620 must be oriented sothat the apertures 676b on the inflator mounting flange 676a are alignedwith the apertures 654 on the second housing member 627. (As with theinflator 520, the inflator 620 may be "correctly" aligned relative tothe reaction device 615 in four different orientations.) Once theinflator 620 is correctly positioned and aligned, appropriate fasteners691 are used to couple the inflator to the second housing member 627. Itmay be noted that, in the completed airbag assembly 610, the space inthe reaction device 615 below the dispensing portion 676c of theinflator 620 remains essentially vacant.

Alternatively, the inflator 620 may be coupled to the second housingmember 628 prior to the positioning and/or coupling of the housingmembers together.

A modified version of the airbag assembly 610, namely an airbag assembly610', is shown in FIG. 21. (Like parts are designated by like referencenumerals, with the parts of the airbag assembly 610' being followed by asingle prime (').) The airbag assembly 610' is essentially identical tothe airbag assembly 610 except for the shape of the first and secondhousing members 627' and 628'. Specifically the housing members 627' and628' are modified so that the height (i.e., the distance betweenparallel portions of the housing members) of the rear region of thecavity 629' is essentially the same as the height of the front region ofthe cavity. Additionally, in the completed airbag assembly 610', the bag680' is folded so that it occupies the space below the dispensingportion 676c' of the inflator 620'.

Another modified version of the airbag assembly 610, namely an airbagassembly 610", is shown in FIG. 22. (Like parts are designated by likereference numerals, with the parts of the airbag assembly 610" beingfollowed by a double prime (").) The airbag assembly 610" is essentiallyidentical to the airbag assembly 610 except that the first housingmember 627" is also provided with an inflator-supporting opening 653"and another inflator 620" is also externally mounted to the reactiondevice 615."

Airbag Assembly 710

The airbag assembly 710 (FIG. 23) includes a reaction device, acylindrical inflator 720, and an airbag 725. The reaction deviceincludes a first housing member 727 and a second housing member 728.These housing members are configured to capture and orient thecylindrical inflator 720 in the cavity of the reaction device as thehousing members are being coupled together.

The airbag assembly 710 also includes a cover 731 for the deploymentopening. In the illustrated assembly 710, the cover 731 includes areceptacle 731a which is adapted to separate into segments duringdeployment of the airbag assembly 710. In the completed airbag assembly710, the receptacle forms a container for the airbag 725. Two L-shaped(in cross-section) coupling tabs 731b are provided on the top and bottomof the receptacle 731a. Each tab extends frontward from the receptacle731a and then turns inward. The inwardly extending portion of eachcoupling tab 731b is provided with a pair of apertures. (Apertures arenot visible in the illustrated view.) As is explained in more detailbelow, the coupling flanges 731b are used to attach the cover 731 to thereaction device.

The first and second housing members 727 and 728 are preferably formedby drawing or stamping aluminum, steel or other appropriate materialinto the desired shape. The first housing member 727 is a generallybox-like structure having a base plate 732, parallel top and bottomwalls 733 and 734, and parallel side walls 735 and 736. The walls733-736 extend rearwardly from, and form a perpendicular border around,the base plate 732. A pair of coupling tabs 737 project perpendicularlyoutward from the distal edge of each of the top and bottom walls 733 and734. Each tab 737 includes apertures 738.

The first housing member 727 includes an inflator support structure 740formed in its base plate 732 and its side walls 735 and 736.Specifically, the inflator support structure 740 includes a cradle 751,or a concave semi-cylindrical compression, formed in the base plate 732.The cradle 751 is sized to generously surround a front portion of theinflator 720. Additionally, the inflator support structure 740 includesa semi-circular notch 753a formed in the side wall 735 and a largersemi-circular notch 753b formed in the side wall 736. As is explained inmore detail below, the notches 753a and 753b are sized and arranged toaccommodate certain portions of the inflator 720.

The second housing member 728 is a generally box-like structure having abase plate 754, parallel top and bottom walls 755 and 756, and parallelside walls 757 and 758. The walls 755-758 extend rearwardly from, andform a perpendicular border around, the base plate 754. A pair ofcoupling tabs 759 project perpendicularly outwardly from the proximateedge of each of the top and bottom walls 755 and 756. Each tab 759includes apertures 760.

The second housing member 728 includes an inflator support structure 765formed in its base plate 754 and its side walls 757 and 758.Specifically, the inflator support structure 765 includes a cradle 766,or a convex semi-cylindrical compression, formed in the base plate 754.The cradle 766 is sized to generously surround a rear portion of theinflator 720. Additionally, the inflator support structure 765 includesa semi-circular notch 767a formed in the side wall 757 and a largersemi-circular notch 767b formed in the side wall 758. As is explained inmore detail below, the second housing member 728 also functions as adiffuser in the completed airbag assembly 710. To this end, the cradle766 (or the convex semi-cylindrical compression) includes a plurality ofopenings or slots 768.

Thus, in contrast to the airbag assemblies discussed above, the firstand second housing members 727 and 728 of the airbag assembly 710 arenot essentially identical.

The inflator 720 is substantially the same as the inflator 120 of theairbag assembly 110. Accordingly, the inflator 720 comprises acylindrical housing 776 which is bottle-shaped and includes a neck 776a.Squib wires 777 project outwardly from the distal end of the neck 776aand a plurality of dispensing nozzles 778 are located around the entireperiphery of the neck 776a. At the onset of a collision, an activationassembly (which includes the squib wires 777) releases the pressurizedinflation fluid so that it flows through the nozzles 778 in a 360°pattern. In the inflator 720, a disk-shaped projection 779 projectsoutwardly from the "non-necked" end of the housing 776.

The inflator 720, like the inflator 120, can be used with a diffuser todirect the inflation fluid uniformly into the airbag 725. As wasdiscussed above, in the illustrated airbag assembly 710, a diffuser isincorporated into the second housing member 728 or, more particularly,its base plate 754. During deployment of the completed airbag assembly710, inflation fluid will flow from the bottle 776, into the annularmixing chamber formed by the cradles 751 and 766, through the openings768 in the base plate 754, and into the airbag 725.

The airbag 725 includes a folded inflatable bag 780 which is formed froma fabric such as nylon and which includes a mouth defining an inflationfluid inlet. The airbag 725 also includes a continuous frame 782attached to the bag 780. The frame 782 is generally rectangular in shapeand includes parallel side members 783 and 784, and parallel top andbottom members 785 and 786. The continuous frame 782 is of a somewhatdifferent construction than the continuous frames of the airbagassemblies discussed above. Particularly, the front surfaces of theframe members 783-786 are co-planar so that they form a flat surface.Additionally, a pair of coupling tabs 787 project perpendicularlyoutwardly from the front edge of each of the top and bottom members 785and 786. Each tab 787 includes apertures 788.

In the assembly of the airbag assembly 710, the inflator 720 isinitially placed in a predetermined orientation in the first housingmember 727. The placement of the inflator 720 particularly includespositioning the bottle neck 776a in the notch 753a in the side wall 735and positioning the projection 779 in the notch 753b in the side wall736. As with the inflator 120, the inflator 720 does not have to beradially aligned within the reaction device. In other words, because thenozzles 778 are arranged in a 360° pattern, the inflator 720 may belocated in any rotational orientation within the inflator supportstructure 740.

Once the inflator 720 has been positioned in the first housing member727, the second housing member 728 is placed adjacent to the firsthousing member 727. The second housing member 728 is aligned with thefirst housing member 727 in such a manner that the inflator 720 issupported in a predetermined orientation within the cavity of thereaction device. In this predetermined orientation, the distal end ofthe bottle neck 776a is tightly secured within the circular openingformed by the semi-circular notches 753a and 767a, the projection 779 istightly secured within the circular opening formed by the semi-circularnotches 753b and 767b, and the remaining portions of the inflator 720(including the dispensing nozzles 778) are generously surrounded by andspaced from the cradles 751 and 766. Additionally, when the first andsecond housing members 727 and 728 are properly aligned, thecorresponding coupling tabs 737 and 759 are located in adjacent,side-by-side relation, and the corresponding apertures 738 and 760 arealigned with each other.

The first and second housing members 727 and 728 may then be coupledtogether using any suitable method to form the reaction device. As withthe airbag assembly 110, the first and second housing members 727 and728 must be sealed to one another and to the inflator 720 to prevent theescape of inflation fluid.

Thereafter, the airbag 725 and the cover 731 may be coupled to thereaction device. However, in the illustrated airbag assembly 710, theairbag 725 and the cover 731 are coupled to the housing members 727 and728 at the same time the housing members are being coupled to eachother. Specifically, the inflatable bag 780 and the continuous frame 782are inserted into the receptacle 731a of the cover 731. Additionally,the L-shaped coupling tabs 731b are positioned around the frame couplingtabs 787 in such a manner that the corresponding apertures are aligned.

The airbag frame 782 (with the cover 731 coupled thereto) is thenpositioned around the perpendicular border of the second housing member728 (i.e., the border formed by the walls 755-758 around the base plate754). When properly positioned the corresponding coupling tabs (i.e.,the tabs 787 of the frame 782, the tabs 731b of the cover 731, the tabs759 of the second housing member 728, and the tabs 737 of the firsthousing member 727) are located in adjacent, side-by-side relation, andthe corresponding apertures on these tabs are aligned with each other.

Conventional fasteners (not shown) may then be inserted through thealigned apertures to couple the housing members 727 and 728 together toform the reaction device and to couple the airbag 725 and the cover 731to the reaction device.

Alternative Inflator Support Structures

While applicants have disclosed several preferred structures andtechniques for capturing and supporting an inflator as a reaction deviceis being formed, it is believed that other structures and techniques maybe used without departing from the broader concepts of the invention.For example, a cradle for the inflator can be formed by a separatemember which is coupled to one or more of the housing members and whichsupports an inflator in spaced relation to the housing members as thereaction device and the inflator are assembled. The cradle can beformed, e.g., as a frame with a portion having a V-shaped configuration,or as a piece of spring steel or spring wire configured to form aV-shaped cradle. When the cradle is formed as a frame with a portionhaving a V-shaped configuration, the frame can be secured to one of thehousing members, e.g. by means of a locking screw (which can be a setscrew that allows some range of adjustment of the position of the framerelative to the housing members). When the cradle is formed by a pieceof spring steel or spring wire, a portion of the spring steel or springwire can be secured directly to one of the housing members.

Moreover, a spring structure can be integrally incorporated into thereaction device in such a way that the inflator is resiliently held inthe cradle as the reaction device is being formed. The spring structurecan act between the cradle and one of the housing members, or it can actbetween the inflator and one of the housing members. For example, whenthe cradle is formed as a frame with a portion having a V-shapedconfiguration, the spring structure can comprise a coil spring whichsurrounds the shaft of the locking screw which secures the frame to oneof the housing members. The spring structure can also comprise aseparate spring member (e.g. a spring clip formed of spring wire), whichis secured to one of the housing members and which acts between thehousing member and the inflator to hold the inflator in the cradleformed in the frame. When the cradle is formed by a piece of springsteel or spring wire, the piece of spring steel or the piece of springwire also forms the spring structure.

A cradle and spring structure which hold an inflator in spaced relationto the housing members, and resiliently hold the inflator in the cradlewould allow for some expansion of the inflator housing as gases arebeing directed from the inflator. Such a feature would be useful inconnection with inflators in which gases are generated at elevatedtemperatures.

Alternative Airbag Support Structures

Although the airbag support structures of the above-identified airbagassemblies included channels, "channel-less" airbag support structuresare possible with, and contemplated by, the present invention. Forexample, in the airbag assembly 210, the airbag support structures 245and 267 of the housing members 227 and 228 could constitute flatsurfaces with appropriately spaced apertures to receive the locatorstuds 287 and 288 of the airbag frame 282. In the assembly of the airbagassembly 210, the airbag 225 would be initially placed in apredetermined orientation in the first housing member 227 and thisplacement would include inserting the locator studs 288 through theapertures of the first airbag support structure 245. Thereafter, thesecond housing member 228 would be placed over, and aligned with, thefirst housing member 227 so that the locator studs 287 projected throughthe apertures of the second airbag support structure 267. In thismanner, the housing members would be configured to capture and orientthe airbag 225 in the cavity of the reaction device 215 as the housingmembers are being coupled together.

Alternatively, "channel-less" versions of the airbag support structures245 and 267 could constitute flat surfaces with appropriately spacedapertures to receive rivets. In this version, the continuous frame 282would include apertures (instead of locator studs) positioned to alignwith the apertures in the airbag support structures. Preferably, theairbag support structures would also include at least one locatingaperture and the continuous frame 282 would also include at least onelocator stud. In the assembly of the airbag assembly 210, the airbag 225would be initially placed in a predetermined orientation in the firsthousing member 227 and this placement would include inserting thelocator stud through the locating aperture of the first airbag supportstructure 245. This insertion would ensure that the corresponding rivetapertures are appropriately aligned. Thereafter, the second housingmember 228 would be placed over, and aligned with, the first housingmember 227 so that the remaining corresponding rivet apertures areappropriately aligned. Thereafter rivets (or other suitable fasteners)would be used to secure the airbag 225 to the housing members. In thismanner, the housing members would be configured to capture and orientthe airbag 225 in the cavity of the reaction device 215 as the housingmembers are being coupled together.

Closing

One may now appreciate that the present invention provides an airbagassembly formed by a plurality of housing members adapted to be coupledtogether. The housing members are configured to capture and orient aninflator and/or an airbag in the cavity of the reaction device as thehousing members are being coupled together. In this manner, the inflatorand/or the airbag are coupled with the reaction device as the reactiondevice is being formed.

Although the invention has been shown and described with respect tocertain preferred embodiments, it is obvious that equivalent alterationsand modifications will occur to others skilled in the art upon thereading and understanding of this specification. For example, any of thefeatures included in one illustrated airbag assembly could beincorporated, where appropriate, into another illustrated airbagassembly. The present invention includes all such equivalent alterationsand modifications and is limited only by the scope of the followingclaims.

What is claimed is:
 1. A vehicle safety apparatus comprising:aninflatable air bag for, when inflated, restraining a vehicle occupant;at least one actuatable inflator for, when actuated, releasing inflationfluid through openings in said inflator to inflate said air bag, saidinflator including a container containing a source of inflation fluid;first and second housing members coupled together to form a reactioncan, said first and second housing members defining a cavity containingsaid air bag and a deployment opening through which said air bag isdeployed upon inflation of said air bag; means supporting said inflatorwith said inflator openings in communication with said cavity; and saidfirst and second housing members including means for capturing said airbag in said cavity and retaining said air bag in a predeterminedorientation in said cavity as said first and second housing members arecoupled together to form said reaction can.
 2. A vehicle safetyapparatus according to claim 1 further comprising means for capturingsaid inflator in said cavity and retaining said inflator in apredetermined orientation in said cavity as said first and secondhousing members are coupled together to form said reaction can.
 3. Avehicle safety apparatus according to claim 1 wherein said at least oneinflator includes a cylindrical inflator.
 4. A vehicle safety apparatusaccording to claim 1 wherein said deployment opening has an ellipticalshape.
 5. A vehicle safety apparatus according to claim 1 wherein saidfirst and second housing members include means for defining a venturichannel extending between said inflator and said air bag when said firstand second housing members are coupled together.
 6. A vehicle safetyapparatus according to claim 1 further comprising a cover and a bandwhich can be tensioned around said cover, said first and second housingmembers including means for tensioning said band around said cover tocouple said cover to said reaction can.
 7. A vehicle safety apparatusaccording to claim 1 wherein at least one of said first and secondhousing members includes a diffuser for dispersing inflation fluid flowfrom said inflator.
 8. A vehicle safety apparatus according to claim 1wherein said first and second housing members are essentially identical.9. A vehicle safety apparatus according to claim 1 wherein each of saidfirst and second housing members comprises a single piece of metalmaterial.
 10. A vehicle safety apparatus according to claim 1 whereineach of said first and second housing members comprises a single pieceof polymeric material.
 11. A vehicle safety apparatus according to claim1 wherein at least one of said first and second housing members includesmeans for defining a number of aspiration openings.
 12. A vehicle safetyapparatus according to claim 1 further comprising a diffuser fordispersing inflation fluid flow from said inflator, said first andsecond housing members including means for capturing said diffuser andretaining said diffuser in a predetermined orientation in said cavity assaid first and second housing members are being coupled together to formsaid reaction can.
 13. A vehicle safety apparatus comprising:aninflatable air bag for, when inflated, restraining a vehicle occupant;at least one actuatable inflator for, when actuated, releasing inflationfluid to inflate said air bag, said inflator including a containercontaining a source of inflation fluid; first and second housing memberscoupled together to form a reaction can having a cavity and a deploymentopening through which said air bag is deployed upon inflation of saidair bag, said first and second housing members including means forcapturing one of said inflator and said air bag in said cavity andretaining the one of said inflator and said air bag in a predeterminedorientation in said cavity as said first and second housing members arecoupled together to form said reaction can; and each of said first andsecond housing members having a generally U-shaped structure in aportion thereof and cooperating with the generally U-shaped structure ofthe other one of said first and second housing members to define saiddeployment opening in said reaction can as said first and second housingmembers are coupled together to form said reaction can.
 14. A vehiclesafety apparatus according to claim 13 further comprising means forcapturing the other one of said inflator and said air bag in said cavityand retaining the other one of said inflator and said air bag in apredetermined orientation in said cavity as said first and secondhousing members are coupled together to form said reaction can.
 15. Avehicle safety apparatus according to claim 13 wherein said at least oneinflator includes a cylindrical inflator.
 16. A vehicle safety apparatusaccording to claim 13 wherein said deployment opening has an ellipticalshape.
 17. A vehicle safety apparatus according to claim 13 wherein saidfirst and second housing members include means for defining a venturichannel extending between said inflator and said air bag when said firstand second housing members are coupled together.
 18. A vehicle safetyapparatus according to claim 13 further comprising a cover and a bandwhich can be tensioned around said cover, said first and second housingmembers including means for tensioning said band around said cover tocouple said cover to said reaction can.
 19. A vehicle safety apparatusaccording to claim 13 wherein at least one of said first and secondhousing members includes a diffuser for dispersing inflation fluid flowfrom said inflator.
 20. A vehicle safety apparatus according to claim 13wherein said first and second housing members are essentially identical.21. A vehicle safety apparatus according to claim 13 wherein each ofsaid first and second housing members comprises a single piece of metalmaterial.
 22. A vehicle safety apparatus according to claim 13 whereineach of said first and second housing members comprises a single pieceof polymeric material.
 23. A vehicle safety apparatus according to claim13 wherein at least one of said first and second housing membersincludes means for defining a number of aspiration openings.
 24. Avehicle safety apparatus according to claim 13 further comprising adiffuser for dispersing inflation fluid flow from said inflator, saidfirst and second housing members including means for capturing saiddiffuser and retaining said diffuser in a predetermined orientation insaid cavity as said first and second housing members are coupledtogether to form said reaction can.
 25. A method of assembling an airbag assembly, said method comprising the steps of:coupling a firsthousing member and a second housing member together to form a reactioncan having a cavity and a deployment opening through which an air bagmay be deployed; capturing at least one of an air bag and an inflator inthe cavity of the reaction can and retaining the at least one of the airbag and the inflator in a predetermined orientation in the cavity as thefirst and second housing members are coupled together to form thereaction can; and moving a generally U-shaped structure of one of thefirst and second housing members into engagement with a generallyU-shaped structure of the other one of the first and second members toform the deployment opening in the reaction can as the at least one ofthe air bag and the inflator is being captured and retained in thepredetermined orientation in the cavity.
 26. A method according to claim25 further comprising the step of placing the air bag in a predeterminedorientation in the first housing member.
 27. A method according to claim26 wherein the step of coupling includes the steps of (i) positioningthe second housing member adjacent to the first housing member after theair bag has been placed in the first housing member, and (ii) aligningthe first and second housing members to capture and retain the air bagin a predetermined position within the cavity in the reaction can as thefirst and second housing members are coupled together.
 28. A methodaccording to claim 25 further comprising the step of placing theinflator in a predetermined orientation in the first housing member. 29.A method according to claim 28 wherein the step of coupling includes thesteps of (i) positioning the second housing member adjacent to the firsthousing member after the inflator has been placed in the first housingmember, and (ii) aligning the first and second members to capture andretain the inflator within the cavity in the reaction can as the firstand second housing members are coupled together.
 30. A vehicle safetyapparatus comprising:a housing including a first portion and a secondportion which define a first chamber in said housing, at least one ofsaid first and second portions having a series of fastener openings; aninflator disposed in said first chamber between said first and secondportions of said housing, said inflator including a wall defining asecond chamber in said inflator, an inflation fluid source disposed insaid second chamber in said inflator, said inflator wall having an outersurface extending in a given direction between first and second oppositeend portions of said inflator; an inflatable vehicle occupant restraintattached to said housing and having an inflation fluid opening; saidfirst and second portions of said housing clamping against said outersurface of said inflator, said first and second portions of said housingdefining said first chamber which (i) extends between said clamped endportions of said inflator and (ii) receives inflation fluid from saidinflator, said first and second portions of said housing cooperating todirect inflation fluid from said first chamber into the inflation fluidopening in said occupant restraint; and a plurality of fastenersextending through said fastener openings in said at least one portion ofsaid housing, said fasteners connecting said first portion of saidhousing with said second portion of said housing.
 31. A vehicle safetyapparatus according to claim 30 wherein (i) said first and secondopposite end portions of said inflator are opposite cylindrical end wallportions of said inflator and (ii) said outer surface of said inflatoris a cylindrical outer surface which has a longitudinal central axisextending in said given direction between said first and second oppositecylindrical end wall portions of said inflator, said first and secondportions of said housing clamping against said cylindrical outer surfaceof said inflator in a direction perpendicular to said longitudinalcentral axis extending in said given direction.
 32. An airbag assemblyincluding a reaction device, an inflator coupled to said reactiondevice, and an airbag also coupled to said reaction device;said reactiondevice comprising a plurality of housing members adapted to be coupledtogether to form said reaction device; said reaction device defining acavity and a deployment opening; said plurality of housing members beingconfigured to capture at least one of said inflator and said airbag insaid cavity and to retain said at least one of said inflator and saidairbag in a predetermined orientation in said cavity as said housingmembers are coupled together; said plurality of housing membersconsisting essentially of a first housing member and a second housingmember; said first and second housing members each including an inflatorsupport structure formed in one piece with the respective housingmember; each of said inflator support structures including a cradle,each cradle having a configuration which matches the configuration of atleast a portion of said inflator, each cradle cooperating to capture andsupport said inflator in said predetermined orientation; said inflatorbeing a cylindrical inflator comprising a cylindrical housing enclosinga source of inflation fluid, squib wires projecting outwardly from oneend of said cylindrical housing, and a plurality of dispensing nozzles;and a resilient biasing device located so as to resiliently hold theinflator in said cradle as said housing members are coupled together;said resilient biasing device comprising a spring formed in one piecewith one of said housing members, said spring being located so as toengage the exterior of the inflator and to resiliently press theinflator against the other of said housing members as said housingmembers are coupled together.